1

INDUSTRIAL TRAINING REPORT

COAL BASED THERMAL POWER PLANT
4 X 300 MW

Dist. RATNAGIRI
MAHARASHTRA



SUBMITTED BY:-
VARUN MISHRA
Graphic Era University, Dehra Dun, Uttarakhand
ENERGY LIMITED
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ACKNOWLEDGEMENT


I am extremely grateful to Mr Vijay Sinha (Head, JSW Energy Ltd. , HR Department,
Mumbai ) and Mr Anand Barve (HOD- HR Department, Ratnagiri ) for giving me this golden
opportunity to be a part of JSW Energy Ltd. Ratnagiri and doing my internship at power
plant.
I would like to express my gratitude and thank Mr. Vijay Paranjpye ( Head of Plant )
Mr. Y.K. Chhabra (GM-O&M) , Mr. Kartikeya Misra (DGM, Electrical-O&M) , Mr. Sanjay
Hardikar ( Electrical Dept.) and the entire team of operation and maintenance at Ratnagiri for
their able guidance and support throughout the training period.
I also thank all the employees of JSW Energy Ltd., Ratnagiri for facilitating my training and
for their co-operation and support.




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CONTENTS
TITLE PAGE NO.

INTRODUCTION 4

THERMAL POWER PLANT 6


BOILER 8

STEAM TURBINE 9

GENERATOR 10

WORKING 12

TRANSFORMER
o GENERATING TRANSFORMER 15
o STATION TRANSFORMER 16
o UNIT AUXILIARY TRANSFORMER 16


ELECTRICAL DISTRIBUTION NETWORK 17

CONTROL ROOM 19

CONCLUSION 20
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INTRODUCTION
JSW Group is one of the leading engineering technology groups of India and with a capacity
of 14 million tonnes per annum, it is the biggest private sector steel producer in India. JSW
Steel and JSW Ispat are the flagship companies of the group in steel sector. JSW Energy Ltd.
is one of the leading private power generating company in India with an installed capacity of
2600 MW across three locations i.e. Vijayanagar (Karnataka), Ratnagiri (Maharashtra) and
Barmer (Rajasthan). The Group also has interests in infrastructure (Ports) and cement (JSW
Cemnets) and IT (J Soft).
JSW Energy Limited owns and operates a coal based thermal power plant situated at Jaigad,
district Ratnagiri, Maharashtra. It is located on the western coastline of India.
Capacity - The capacity of power station is 4x300MW. There are four units and each unit
produces 300MW, therefore the total capacity of the power plant is 1200MW.
Power Evacuation - evacuation of power is through transmission system of 400KV line to
Koyna and Karad sub stations of Maharashtra State Electricity Transmission Company
Limited (MSETCL). Two lines carry the power generated to Koyna and Karad and from
there it flows into the entire grid of Maharashtra. The state of Maharashtra is a part of
Western Regional Power grid.
Coal and coal transportation -- The coal is imported by the JSW Energy from South Africa
and Indonesia at the JSW Jaigarh Port owned by JSW Group. The coal gets shipped from
Port Richards Bay at South Africa and various ports in Indonesia in various size shipments
like Panamax (70,000 tons load per ship). Then, coal is unloaded at Jaigarh Port where there
are two coal unloading berths. From here, it is stored in coalyard through Stacker Reclaimer.
The plant consumes around 4 million tonnes of coal per annum. The coal calorific value is
between 4400 kcal/kg (Low CV) to 5500 Kcal/kg (High CV).
Area- The plant premises has an area of around 330 acres and situated next to the port. Apart
from this there is some additional area for green belt.
Water- The plant uses sea water for condenser cooling which it takes from sea water intake at
sea adjoining the plant.
The fresh water is lifted from Bav River which is around 42 kms from the plant. From there it
is conveyed through a water pipeline of 42 kms via the Nevli pumphouse.The plant consumes
around 5 million litres of raw water for port and power plant operations including plantation.
Sale of Power- The power from Unit 1 i.e. 300 MW is sold to Maharashtra State Electricity
Distribution Company Limited (MSEDCL), 300 MW from Unit 3 is Captive Power Plant for
Group Company JSW Ispat and remaining 600 MW from Units 2 and 4 are sold in open
market through merchant route.
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Equipment- the Steam Turbine Generator and the boiler equipments are manufactured by
Shanghai Electric Company, China, balance of plant is supplied by various reputed Indian
vendors and the switchyard and the switchgears are of ABB make.
Switchyard- The switchyard of the plant is Gas Insulated Switchyard (GIS) with SF6 as gas
insulator. The use of the gas insulator makes the switchyard very compact and is the most
efficient insulator. It is one of the very few Gas Insulated switchyards in the country. There
are four units, each unit generates power at generator terminals at 20 kV and then it is stepped
up to 400 KV for transmission.
Environment The Company believes that development and environment protection go hand
in hand. Fly ash generated is captured in an Electrostatic Precipitator (ESP), a Flue Gas De-
sulphurisation (FGD) plant is being installed currently, to reduce the amount of sulphur
oxides in the environment.
The demand of electricity has been increasing due to rapid industrialization and large scale
use of electricity for irrigation, domestic and commercial purposes. Therefore the group has
set up a power plant to meet the demand with improved quality and standards. This power
plant has bridged the power supply demand gap and helped to reduce the power deficit in the
state of Maharashtra.















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THERMAL POWER PLANT


Photo- 4X300 MW JSW Energy Ltd Thermal Power Plant at Ratnagiri
A thermal power plant uses heat energy to rotate the turbine for the generation of the
electricity. Here coal is used to obtain heat energy; this heat energy is the steam. The steam is
highly pressurized and then it rotates the turbine of the steam turbine generator. Thermal
power plants are less expensive to set up as compared to hydel or a nuclear power plant as
well as thermal power plant has more generating capacity than any other plant. They can
supply power at peak loads as well. In India coal fired plants account for 56% of the total
installed electrical capacity.
The prime mover in a thermal power plant is steam. Water is heated, turns into steam
and spins a steam turbine which drives an electrical generator. After it passes through the
turbine, the steam is condensed in a condenser and recycled to where it was heated; this is
known as a Rankine cycle. The major drawback in a thermal power plant is that it causes
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environment pollution, measures are been taken by installing devices to reduce it. Therefore
standards have to be maintained by the power plants.
The coal is used to heat and converts water into steam inside the boiler and then the
steam is used to rotate the turbine. Generally, a thermal power plant is divided into three
parts:-
Boiler (Steam generator)
Balance Of Plant (BOP)
Steam turbine generator

The boiler unit consists of the coal handling system, the pulveriser, the furnace, air pre-
heaters, super heaters, reheaters, Electrostatic precipitator (ESP), the PA fan(primary), FD fan
(forced draft),and the ID fan(induced draft) and economiser. The Input to the boiler is coal
and water. Coal is fed to the bunker by conveyor belts and then it is grinded and converted
into coal powder and by the help of PA and FD fan, it is burnt inside the furnace. The water
used is raw water, it is then demineralised in DMP (demineralisation plant). This water is
converted into steam by the burning coal. The steam is superheated and reheated in the boiler
and then fed to the steam turbine. The ESP extracts the gas produced by burning of coal, by
the help of ID fan and it reduces the content of the harmful gasses. The flyash is collected in
the ESP unit which is used in cement plant. Through the ID fan the smoke exits through the
chimneys.
The steam produced from the boiler is fed to the steam turbine generator section
which consists of the steam turbine, generator, the condenser, low pressure heater (LPH),
high pressure heaters (HPH), the dearator, and the boiler feed pumps (BFP). The steam is
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recycled but during the process there is loss of steam therefore continuous raw water intake
process is to done. The generator is a 355MVA, 20KV with a brushless exciter. This
generated voltage is step-up to 400KV for transmission and also used for running the
auxiliaries. It also consists of the generating transformers, the station transformers, the unit
auxiliary transformer and the switchyard. Rest of the equipments such as cooling water
pumps, cooling tower, circulating water pumps and the DMP comes under the category of
balance of plant. The protection for the electrical equipments is the major concern, therefore
protection panel with back up have been installed, so that there is no interruption in the power
generation. Emergency back-up have been provided by a UPS (uninterrupted power supply)
battery bank and DG set (diesel generator).

BOILER
The boiler is the steam generator. There are two inputs to the boiler, coal and water
and the output is the steam. The boiler consists of the super heaters, reheaters, economiser,
air pre-heaters and soot blowers. The coal is fired in the furnace by tangential firing. Initially
the coal is fired by oil, once it is combusted the oil is removed. Inside the furnace when coal
burns it leaves soot. This soot get deposited on the water tubes, thus reducing the heat and
water contact and reducing the boiler efficiency, therefore short reactable and long reactable
soot blowers are used which prevents the soot to get deposit on the water tubes. The steam
produced in the boiler is collected at the top inside the boiler drum, from there it is made to
flow to the superheater, where its pressure increases and then to the steam turbine. The boiler
used is a coal fired and water run i.e. coal is fired inside the furnace and water tubes are
running inside the furnace, which converts water into steam inside the tube only. The boiler
used at the plant is manufactured by the Shanghai Electric and is a sub-critical natural
circulation type boiler.
The rating of the boiler is as follows:-
SUPERHEATED STEAM
Flow 1015 t/hr
Pressure 17.5 MPa(g)
Temp. 541 C

REHEATED STEAM
Flow 840.7 t/hr
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Pressure 3.72/3.5 MPa(g)
Temp. 323/541 C

The boiler consists of two passes, one comprises of the furnace and the
other contains the superheaters, reheaters, and the economiser. The height of the boiler is
measured in meters and is nearly about 70 meters. The PA fan, FD fan, ID fan, the coal mill
and the electrostatic precipitator (ESP) comes under the category of boiler.

STEAM TURBINE
A steam turbine is a device that extracts thermal energy from pressurized steam and
uses it to do mechanical work on a rotating output shaft. Because the turbine generates rotary
motion, it is particularly suited to be used to drive an electrical generator. The steam turbine
generator is rated for 300MW continuous output at generator terminals. The steam turbine
would be a reheat extraction condensing turbine. The generator is installed with complete
protection system of switchgears, lubricating and control oil systems, turbine drain system
and HP/LP (high pressure/low pressure) by-pass system. It is operated by turbine supervisory
instrumentation.
The steam turbine is in three parts-
High Pressure Turbine (HPT)
Intermediate Pressure turbine (IPT)
Low Pressure turbine (LPT)
The main steam line (MSL) from the boiler superheater is fed directly to HPT and then this
steam is feedback, through CRH (cold reheat) to reheater and then fed to IPT and LPT.
MSL






HRH
HPT IPT LPT
CRH
To Rotor
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GENERATOR
Generator converts the mechanical energy into electrical energy. Here the generator will
generate rated power of 300MW at 20kV, 3-phase at 50Hz and 0.85 power factor. The
generator will rotate at synchronous speed of 3000 RPM, since it is a 2-pole ac machine with
50Hz frequency. The generator winding is star connected with phase and neutral terminals
brought out to an accessible point. The neutral of the star connection is grounded through
neutral grounding transformer. The generator is having air-cooling for stator windings, stator
core and rotor. The output of the main exciter which is AC power is fed directly to rotating
diode to convert into DC power and the same power is fed to rotor winding without
involvement of field breaker. The main exciter, Permanent Magnet Generator (PMG) and the
AVR (automatic voltage regulator) are the components of the excitation system. Generator
windings are provided with class-F insulation. A general description of the generator is as
follows:-
RATING 300 MW, 355 MVA
VOLTAGE 20
CURRENT 10.2 KA
POWER
FACTOR
0.85

REVOLUTIONS
3000 RPM
CONNECTION
Star with Neutral Grounded
Transformer

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CORE

The generator protection system is provided, GPR (generator relay panel). It is
located in the control room and is also protected by the other groups such as generator
differential protection, earth fault protection, generator reverse power protection and
generator over voltage protection and etc. The output voltage from the generator is obtained
through IPBD (isolated phase bus duct) to the generating transformer (GT) and station and
unit auxiliary transformers (UAT). At generator output there is a GCB (generator circuit
breaker), it is used for synchronization and also for protection.


STATOR AND ROTOR





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WORKING
For generating output electricity, we need two inputs coal and water. Coal produces
heat energy which converts water into steam and steam is used to rotate the steam turbine.
The coal is burnt in the furnace at high temperature and pressure, this produces heat energy.
The water is pumped through the water walls in the boiler which is converted into steam by
the heat energy, the steam produced is superheated i.e. more increase in temperature and
pressure and then forced to rotate the turbine. The turbine is connected to the rotor of the
generator, which generates an output voltage. The working of a coal based thermal power
plant is described below.
Coal imported from the South Africa and Indonesia is collected in the coal yard at port.
By the help of conveyor belts, the coal from the coal yard is transferred to the coal bunker.
There are two conveyor belts which serves coal to the coal bunkers of each unit. There are six
coal bunkers for each unit. Continuous supply of coal in the bunker with two conveyor belts
is performed by the V-plough. They are used to divide the coal for each unit. The coal
bunkers are also known as Silo. The size of the coal dropped into the bunker is uneven and
cannot be directly feed to the furnace. From the bunker the coal is feed to the gravimetric coal
feeder. It is a continuous weighing machine used to weigh and feed a specific amount of coal
from coal bunker to the coal mill or pulveriser. Inside the coal mill the coal is grinded and
converted into a powder, the size of the coal particle after it has been crushed is about 80
micro mm. The coal powder is fed to the coal burners corners of the furnace by the help of
PA fan. The PA fan forces the powder to flow to the burner corner of the furnace. There are
hot pa fan and cold pa fan. The air preheaters installed at the PA fan which increases the
temperature of the coal before burning. Inside the furnace when coal is input through the coal
burner corners, the coal is burnt by tangential firing inside the furnace. Now the coal is fired,
for the combustion of the coal, it requires air which is provided by the FD (forced draft) fan.
By burning of the coal heat energy is produced and the temp. inside the boiler is nearly equal
to 540 degree Celsius.

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Another input to the boiler is the water. We cannot directly feed the raw water into the
boiler as it contains chemicals which can cause corrosion in the water pipes and in the boiler
itself. Therefore chemical dozing is performed in the demineralization plant (DMP). The
dozing of ammonia, hydrazine and phosphate is done in the plant. The raw water is intake to
the DM plant. Here the water is free from impurities and is now pure water. After the
demineralization of water, it is stored in a tank. By the help of hotwell makeup pump the
water is feed to the hot well of the condenser. From the hotwell the condensate extraction
pump (CEP) extracts the water and pumps to gland steam condenser. We do not input water
in the boiler at normal temperature, firstly it temp. and pressure is increased so that it can
easily get converted into steam inside the boiler. The water is circulated through the low
pressure heaters (LPH), two of them are inside the condenser.
The used steam in the condenser is used to increase the temp. inside the
LPH. After that it is further more heated in LPH3 and LPH4. From LPH the line flows to the
deaerator. It is a device used for the removal of oxygen and other dissolved gases from
the feed water to steam-generating boilers. In particular, dissolved oxygen in boiler feed
waters will cause serious corrosion damage in steam systems by attaching to the walls of
metal piping and other metallic equipment and forming oxides(rust). Dissolved carbon
dioxide combines with water to form carbonic acid that causes further corrosion. Extractions
from the intermediate pressure turbine (IPT) are given to the deaerator to increase the temp.
and pressure of the water. Now from deaerator water is sent to the boiler feed pumps (BFP).
It is the heaviest rated machine in the plant of rating 5600kW, 6.6KV 3-phase induction
motor. There are two BFP and one at standby for each unit. The BFP pumps the water to the
High Pressure heaters (HPH). There are three levels of HPH, the water is at very high temp.
and pressure and is pumped to the boiler by Feed Regulation System (FRS). The FRS is done
to control the flow of water into the boiler, it is used to bypass the water to the condenser if
needed. The water from FRS is pumped to the economiser inside the boiler. When the coal
burns, it emits gasses; these gasses are the flue gas. It is used to heat the water inside the
tubes that is why it is known as economiser. Through the economiser the water is pumped to
the boiler drum. It is situated at the top of the boiler and collects the high temp. and high
pressure water. A down comer straight from the boiler drum is directed to the boiler water
walls. The water from the boiler drum flows towards the ring header which is then flowed
into water walls. The heat produced by the burning of the coal heats these water walls and the
water is converted into steam.
This steam is collected in the boiler drum. This steam is made to flow
through few process of more heating. First it is passed through low temperature super heater
(LTSH) and then to the final super heater (FSH). This steam is at very high pressure and is
made to flow to High pressure turbine (HPT) through main steam line (MSL). This steam
rotates the HPT, when this steam is used, it is sent back to the reheater through CRH (cold
reheat). It is reheated and made to flow through hot reheat (HRH) to the intermediate pressure
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turbine (IPT). The IPT and LPT (low pressure turbine) are connected to each other.
Therefore the turbine is rotated and rotates the rotor of the generator and an emf is induced
which results in output voltage of 20KV, this output voltage is step-up to 400KV for
transmission and also used for running plant auxiliaries. The voltage is stepped up by a
generating transformer and power is transmitted to Koyna and Karad.
The steam which used to rotate the IPT and LPT flows to the
condenser. This steam is used to heat the demineralized water inside LPH1 and LPH2. After
that it is made pass through the cool water circulating in the water pipes inside the condenser.
By the help of this cold circulating water, the steam is converted back into water state and
gets collected in the hotwell. This water is extracted by CEP and again the process is
repeated, but during this process there is a loss in steam and water therefore continuous
supply of water has to be provided. The cooling water system is a re-circulating type of
cooling system. The water used for cooling purpose is the sea water. The water is pumped
from the sea water intake pump house (SWIPH), and then collected at fore bay.

After that chlorine dozing is performed and this water is pumped
into the condenser by the help of circulating water pump (CWP). It converts the steam into
water, in this process the cooling water is also heated i.e. its temp. rises. Therefore it has to be
cooled for reuse. The water is cooled by the cooling towers (CT). The cooling system
includes natural draught cooling towers, and then it is collected in CT basin which is again
pumped into the condenser by the help of CWP. Now, in boiler, inside the furnace when the
coal is burnt it produces gasses and leaves soot. To avoid soot to get deposit on the water
tubes, soot blowers are used. The gasses produced due to burning of coal are known as flue
gas. These flue gases have high temp. and is used to heat the incomer water to the boiler
inside the economiser. This flue gas contains harmful gasses, they are oxides of sulphur and
carbon, and therefore they cannot get directly discharge into the atmosphere. For this reason
an Electrostatic Precipitator (ESP) is installed, for reducing the intensity of the harmful
gasses. The ID fan extracts these gases from the ESP and made to eject through the chimney.
The ESP contains hopper heaters, which heats the gas molecules and make them heavier and
are collected in the hopper as fly ash. This fly ash is used in cement plant. The ESP also
consist of collecting rapper motor (CRM) and emitting rapper motor (ERM), to collect the fly
ash into the hopper. A flue gas desulphurication (FGD) is being installed for removing
sulphur oxides from the smoke before discharging it into the atmosphere.
The working of a plant is a process in a form of cycle and is repeated. This process
works continuously. The process of power plant is operated and controlled from the control
room, which are equipped with latest technology of instrumentation and automation system.
All the protection relays and switch gears are operated from the control room only. The
automation systems used are DCS (Distributed Control System), PLC (Programmable Logic
Controller) and SCADA (Supervisory Control And Data Acquisition).

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TRANSFORMER
The main transformers are the generating transformer (GT), Station
transformer and the Unit Auxiliary transformer (UAT) and also there are low rating
transformers used for working of low rating machines and the AC supply distribution board.
Transformers are installed with protection measures, circuit breakers are there which have
their own protection and control panel which can be operated or controlled from the control
room. The highest rating transformer is the generating transformer as it step-up 20 kV to
400kV.

Generating Transformer (GT)
The generator output through IPBD is step-up by a generating transformer. It
will step-up, 20kV generated voltage to 400kV for transmission. The high voltage line of the
GT is connected to 400kV gas insulated switchyard. The GT is a 355MVA with YNd1 i.e.
high voltage star connected and low voltage delta connected. The transformer is OFAF (oil
forced air forced) / ONAF (oil natural air forced)/ ONAN (oil natural air natural) type
cooling. The high voltage winding are connected to the switchyard through circuit breakers,
isolators, and lightning arrestors (LA), they are known as bays. A general description of GT
rating is as follows:-
RATING 355 MVA
VOLTAGE 20 kV / 400 kV
CONNECTION YNd1
TYPE OF COOLING ONAN/ ONAF/ OFAF
IMPEADENCE 14.5% ON 355 MVA BASE

The type of tap changer in GT is on load tap changer with tap range +5% to -10% in steps
of 1.25%. The high voltage winding of the transformer is given a neutral direct to earth. As
GT is highest rating transformer more protection measures have to be taken as they are very
expensive and are not available at instant. The buccholz relays and oil temperature indicator
and the winding temperature indicator are there for protection of the GT.



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Station Transformers
The generating transformers are used for supplying power to the auxiliaries
or the equipments that is common to all the units or for station. There are two station
transformers in the plant. First is connected to unit #1 and Second to Unit #2. The rating of
the station transformer is:-

RATING
31.5 MVA
VOLTAGE 20 kV/6.6 KV
CONNECTION 3-phase,3-winding,Dyn
TYPE OF
COOLING
ONAN/ONAF
IMPEADENCE HV-LV1=17%
HV-LV2=32% on 50MVA BASE

The station transformer input is the generated voltage, 20kV. It is a 3-
phase, 3-winding transformer and serves feeders to the 6.6 kV switchboards for running the
auxiliaries such as CCW (circulating cooling water), and feeders to service station
transformers and ash-handling and coal-handling plant (AHS/CHP) transformers. The station
transformers step down the voltage from 20 kV to 6.6 kV. The 6.6 kV switchboards run the
heavy rating motors of air compressors and a line is fed for the colony supply as well.
Feeders from the station transformers are connected to service station
transformers (SST), demineralising plant (DMP) transformers and the sea water intake pump
house (SWIPH) as well. These all transformers step-down the voltage from 6.6 kV to 415V
for running lower rating equipments. There connection is Dyn11 type. The SST is used to
run crane motor control centre, station voltage distribution board and as well as main light
distribution board. The AHS/CHP transformers are used to run the conveyor belts motors.

Unit Auxiliary Transformer (UAT)
There are two unit auxiliary transformers for each unit to feed auxiliary loads.
The station transformer and the unit auxiliary transformer are of the same rating. The
difference between them is station transformer is used to feed the station load or the load
common to all units and UAT is used to feed a particular unit load or unit auxiliaries. The
constructional difference between them is the station transformer is a 3-phase, 3-winding
17

transformer whereas the UAT is 3-phase, 2-winding transformer. The two UAT of a unit are
connected to each other through bus bars. In case if any one of the UAT stop working, then
the other one is used to supply power. It steps-down the 20kV to 6.6kV for running unit
auxiliaries. The 6.6kV feeders are connected to 6.6kV switchgear panels which are used to
run ID Fan, FD fan and PA fan, CEP (condensate extraction pump) and also to coal mills.
Further feeders are given to Unit Service Transformer (UST) and ESPT (Electrostatic
Precipitator transformer). The two UAT are connected to each other as #U1A is connected
#U2B and #U1B is connected to #U2A. Similarly Unit#3 and Unit#4 are connected.
The Unit Service Transformer (UST) is used to run the unit low voltage rating
auxiliaries (415V), TGMCC- turbine generator motor control centre, BMCC- boiler motor
control centre, TVDB- Turbine Valve distribution board and SBMCC- soot blower motor
control centre. There is a 6.6kV bus bar link given to the Normal Emergency Switchgear
(NE-SWGR) which is backed up by UPS float cum boost charger and diesel generator set.



ELECTRICAL DISTRIBUTION NETWORK
The electrical distribution network of the plant is such that the power is
supplied to all the auxiliaries with back-up and protection measures. The main purpose of the
plant is to protect the equipments as they are costly and are not available at instant. After the
protection of the equipments are installed i.e. the relays, circuit breakers and isolators, then it
should be seen that the auxiliaries are getting continuous supply. Suppose if one of the station
transformer or the UAT is not working, but for working of plant, the auxiliaries should be
running for the generation of the power. Therefore the station transformers and UATs are
connected to each other through feeders and switchgears.
The interconnection is such that the main transformers, the station
transformers are connected to each other through switchgears and UAT through feeders. The
station transformer is having 2-outout winding and are connected as #C1A of ST#1 is
connected to #C2A of ST#2. Similarly #C1B is connected to #C2B. These Transformers step-
down the generated 20 kV to 6.6kV and runs the high rating equipments. It forms a 6.6kV
switchgear panel or switchboard. They are used to run the high voltage machines as CCW
pump (circulating cooling water), air compressors and boiler feed pumps (BFP). Through the
switchgear, they are coupled by incomer and bus-coupler.




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From the 6.6kV, feeder lines are taken to the SST (Service Station
Transformer), AHS/CHP TRF (ash handling system/Coal Handling Plant Transformer), DMP
TRF (Demineralised Plant Transformer) and feeders to SWIPH (sea-water intake pump
house). At SST, the 6.6kV voltage is step-down to 415V, for running low voltage rating
equipments. They are also used to run the distribution boards of the station and machines.
They are connected by the switchgears of 415V. The AHS/CHP is connected to the air
compressor and main lightning distribution board. Similarly DMP-TRF is connected to
CWPH (circulating water pump house) and motor control centre.
In UAT, they are similarly connected as the station transformer is, but the
auxiliaries and equipment are different. It has 6.6kV switchgear then step-down to 415V, by
UST and ESPT. UAT supplies power to the coal mill, forced draft fan, induced draft fan and
primary air fan. The numbers of UST used are two for each unit. They are connected to
TGMCC, BMCC, TVDB, BVDB and other voltage distribution boards. They are also
connected to DC battery back-up through feeders. A bus bar link is there for normal
emergency switchgear panel which are backed-up by the batteries and the DG set (diesel
generator) when emergency or shut down may take place. The ESPT are connected to hopper
hooters, ERM and CRM for treatment of flyash. As some environmental standards have to be
maintained, a FGD (flue gas de-sulphurication) is currently being installed to remove the
oxides of sulphur and reduce intensity of the sulphur gas before discharging it into the
atmosphere.



400 kV GAS INSULATED SWITCHYARD [GIS]
The power generated at 20 kV is step-up to 400 kV by a
generating transformer (GT) and the evacuation of power is through the gas insulated
switchyard. It is one of the few GIS in the country. The gas insulator used is SF
6.
This gas
insulator has very strong dielectric strength and it can absorb the spark of 400 kV when
subjected to the circuit breakers. The switchyard consists of the circuit breakers, isolators,
earth switch, lightning arrestors (LA), the current transformers, the voltage transformers and
the busbars. These equipments are rated for short circuit current of 40 kA for one second.
The steam turbine generator is connected to the GT through GCB (generator circuit breaker),
it is used to synchronize the generator when the plant is initially started, the line is back
charged and then the generation process initiate and when it is synchronized it is connected to
GT. The output to the GT is through the IPBD and the output is taken from the bushes of the
transformers. The output line through the bushes of GT is connected the switchyard with LA,
current transformers (CT), and potential transformers (PT).
There are two 400 kV bus bars, which are coupled by the bus coupler
and also two reactors to absorb the reactive power which results in Ferranti effect. These lines
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are installed with protection measures circuit breakers, isolators and the earth switch. The
circuit breakers are only used when it on-load and isolators are always use when they are off-
load. We use isolators when we have to repair a conductor physically, therefore first we break
the current and then we isolate. Earth switch are used when the line is open by the circuit
breaker and there is charge in the conductor, therefore to make this charge ground we use
earth switch. The layout of LA, CT, PT, Circuit breakers and Isolators is known as a bay. The
PTs (potential transformers) are capacitive voltage transformer since the voltage measured is
of very high voltage. There are protection and control panel for every incoming and outgoing
line. The circuit breakers and the isolators are controlled by relay panels which are located at
switchyard control panels and operated or controlled from the control room. There are
metering devices installed at the switchyard, one is for the plant and the other is installed by
Maharashtra State Electricity Board. There are four outgoing lines from switchyard, two lines
to Karad and two lines to Koyna at 400 kV.


CONTROL ROOM
The operation of the power plant is operated and control from the control
room. There are one common control room for two units. The data is projected on the large
video screen for each unit. There is an Electric Control Panel (ECP), it will comprise of the
generator controls including the monitoring, control and annunciation for the electrical
auxiliary system. Control room also consist of the steam turbine generator, the generating
transformer and unit auxiliary transformers protection and control panels. The control room is
equipped with instrumentation and automation software such as SCADA and PLC
(programmable logic controller). The Distributed Control System (DCS) is used as the
technique of functional distribution of control and monitoring to reduce the risks associated
with failure of any single controlling unit. The DCS has complete control capabilities that
include closed loop control, open loop control, and computation and interfacing for data
acquisition, graphic displays logging, data storage, performance calculations and
management information system. The system allows for CRT operation from the control
desk. The control room is under the operation department and operators works in shift as
plant should be in observation 24x7. The operation is divided into two parts desk operation
and field operation. There is a common shift engineer to organize the shifts so that the control
room is under observation every minute. As the control room is critical to be working for the
working of the plant an Uninterrupted Power supply (UPS) is given separately if there is an
emergency.



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CONCLUSION

With the increase in the urban sector and the industries, it increases the demand of
power supply, which can be achieved by thermal power plant as they are more efficient,
supply power at peak loads and are less expensive. Though the thermal power plant causes
environmental degradation, therefore a sustainable development should be there for
maintaining the balance of the nature and development.
The power plant is installed with latest instrumentation, automation and technology
like SCADA and the Gas Insulated Switchyard [GIS], which makes the working of the power
plant more reliable and easier. As observed by me, there are three key points to be concerned
in the thermal power plant:-
Safety of the employees
Protection of the equipments
Back-up for continuous supply